Reactor

Abstract

This reactor is provided with: a core comprising a plurality of electromagnetic steel plates laminated in the thickness direction; and, a coil comprising wire wound around the core. The electromagnetic steel plate has: a pair of outer components having a first portion that extends in a first direction, and a plurality of second portions that extend from the first portion in a second direction orthogonal to the first direction and are arranged at intervals in the first direction; a central component for connecting the plurality of second portions to each other in the first direction with the second portions opposed from the second direction; and, a plurality of fin formation sections that protrude in the second direction from the end edge of the first portion on the side opposite to the second portion and are arranged at intervals in the first direction.

Description

[Technical field]

[0001] The present disclosure relates to a reactor. This application claims priority to Patent Application No. 2021-159131, filed in Japan on September 29, 2021, the contents of which are incorporated herein by reference. [Background technology]

[0002] Reactors are widely used as electrical components for generating reactance. A reactor includes a core formed by laminating multiple electromagnetic steel sheets, and a coil made of a wire wound around the core (for example, see Patent Document 1 or Patent Document 2 below).

[0003] In order to reduce the overall size of the reactor, there are an increasing number of cases where two coils are mounted on one core. In this case, the core can be formed, for example, by a pair of E-shaped outer parts and an I-shaped central part placed between the outer parts. Two coils are formed by winding wire around each of the central protrusions of the three protrusions of the outer part.

[0004] Here, an air gap is formed between the central protrusion and the central part. Therefore, the magnetic flux density is low around it. On the other hand, since no air gap is formed at the base of the central protrusion, the magnetic flux density tends to be high. As a result, heat may be generated in that area when the reactor is operated. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] JP 2013-93921 A [Patent Document 2] China Utility Model No. 206194495 Specification Summary of the Invention [Problem to be solved by the invention]

[0006] However, conventional reactors have not been provided with sufficient measures against such heat generation, which may affect the stable operation of the reactor.

[0007] The present disclosure has been made to solve the above-mentioned problems, and has an object to provide a reactor that can be operated more stably. [Means for solving the problem]

[0008] In order to solve the above problems, a reactor according to the present disclosure includes a core made of a plurality of electromagnetic steel sheets stacked in a thickness direction, and a coil made of a wire wound around the core, wherein the electromagnetic steel sheets include a pair of outer parts having a first portion extending in a first direction and a plurality of second portions extending from the first portion in a second direction perpendicular to the first direction and arranged at intervals in the first direction, a central part connecting the second portions to each other in the first direction with the plurality of second portions facing each other in the second direction, and a plurality of fin forming portions protruding in the second direction from an edge of the first portion opposite the second portion and arranged at intervals in the first direction. The workpiece is punched out so that the second portions of the multiple outer parts having the same shape engage with each other, thereby forming multiple pairs of the pairs of outer parts, and the outer parts have three of the second portions and are located on the outside in the first direction, and of two second portions having different lengths in the second direction, the length of one second portion having the shorter length is less than the difference between the length of the other second portion in the second direction and twice the width of the one portion in the second direction. Effect of the Invention

[0009] According to the present disclosure, it is possible to provide a reactor that can be operated more stably. [Brief description of the drawings]

[0010] [Figure 1] FIG. 2 is a cross-sectional view showing a configuration of a reactor according to an embodiment of the present disclosure. [Diagram 2] FIG. 4 is an explanatory diagram showing a shape when punching an electromagnetic steel sheet according to an embodiment of the present disclosure. [Figure 3A] FIG. 11 is an explanatory diagram showing a first modified example of a shape when punching an electromagnetic steel sheet according to another embodiment of the present disclosure. [Figure 3B] FIG. 11 is an explanatory diagram showing a second modified example of a shape when punching an electromagnetic steel sheet according to another embodiment of the present disclosure. [Figure 4] FIG. 13 is an explanatory diagram showing a third modified example of a shape when punching an electromagnetic steel sheet according to another embodiment of the present disclosure. [Diagram 5] FIG. 11 is a cross-sectional view showing a configuration of a reactor according to another embodiment of the present disclosure. [Figure 6] 13 is an explanatory diagram showing an example of a shape when a central part is punched out according to another embodiment of the present disclosure. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] (Reactor configuration) Hereinafter, a reactor 100 according to an embodiment of the present disclosure will be described with reference to Fig. 1 and Fig. 2. The reactor 100 is a component used to generate reactance in an electric circuit. As shown in Fig. 1, the reactor 100 includes a core 1 and two coils (a first coil 51 and a second coil 52).

[0012] (Core configuration) The core 1 is formed by laminating in the thickness direction a plurality of plate-shaped electromagnetic steel sheets 90. The electromagnetic steel sheets 90 each have a pair of outer components 1a and one central component 1b.

[0013] The outer part 1a has a first part 11 extending in a first direction D1, three second parts 12 protruding from the first part 11 in a second direction D2 perpendicular to the first direction D1 and arranged at intervals in the first direction D1, and a fin forming portion 13 provided on the edge of the first part 11 opposite the second part 12.

[0014] The first portion 11, the second portion 12, and the fin forming portion 13 are integrally formed. The distance between the second portions 12 in the first direction D1 is the same. Note that "same" here refers to being substantially the same, and manufacturing errors and design tolerances are allowed.

[0015] Of the three second portions 12, the second portion 12 located at the center in the first direction D1 has a dimension in the second direction D2 set smaller than those of the other second portions 12. This is to form an air gap between the central second portion 12 and a central component 1b, which will be described later. The number of second portions 12 is preferably three, but may be two, four or more.

[0016] The fin forming portions 13 are arranged at intervals in the first direction D1. The fin forming portions 13 protrude in the second direction D2 from the first portion 11. The fin forming portions 13 each form a fin 14 when the electromagnetic steel sheets 90 are stacked in the thickness direction.

[0017] Of the pair of outer components 1a, the position of the fin forming portion 13 in the first direction D1 of one outer component 1a is different from the position of the fin forming portion 13 in the other outer component 1a in the first direction D1. Furthermore, as shown in Fig. 2, when the fin forming portions 13 are opposed to each other in the second direction D2 during punching, the fin forming portions 13 are shaped to engage with each other. In other words, the fin forming portions 13 are alternately arranged between the pair of outer components 1a so as to complement each other.

[0018] The central part 1b extends in the first direction D1 so as to connect the three second portions 12 in the first direction D1. The dimension of the central part 1b in the first direction D1 is twice the dimension of the second portions 12 in the second direction D2. The dimension of the central part 1b in the second direction D2 is the same as the distance between the second portions 12 in the first direction D1.

[0019] (Coil configuration) First coil 51 and second coil 52 are each formed by winding a wire several times around second portion 12 in the center in first direction D1. That is, reactor 100 has two independent coils. Various modes proposed so far may be adopted as a method of winding the wire.

[0020] In forming reactor 100, a pair of outer parts 1a and central part 1b punched into the above-described shape are laminated in the thickness direction, and then wire is wound to form first coil 51 and second coil 52. Thereafter, reactor 100 is completed by welding the laminate of central part 1b and the laminate of the pair of outer parts 1a.

[0021] (Regarding punching shapes of electromagnetic steel sheets for reactors) Next, the punched shape of the reactor-use electromagnetic steel sheet 90 will be described with reference to Fig. 2. The die (blade) used to punch the reactor-use electromagnetic steel sheet 90 has the shape shown in Fig. 2. That is, a pair of outer components 1a are arranged so that the second portions 12 face each other. As described above, the fin forming portion 13 is arranged so as to engage with the fin forming portion 13 of the adjacent outer component 1a. Furthermore, at least one of the regions formed between the second portions 12 of the outer components 1a is used as a region for forming the central component 1b.

[0022] (Action and effect) Here, a gap serving as an air gap is formed between the central second portion 12 and the central part 1b in the first direction D1. Therefore, the magnetic flux density is low around the central second portion 12. On the other hand, since no air gap is formed at the base of the central second portion 12 (i.e., the portion connected to the first portion 11), the magnetic flux density tends to be high in this region. As a result, heat may be generated in this region when the reactor 100 is operated. Therefore, the above-mentioned configuration is adopted in this embodiment.

[0023] According to the above configuration, since the fin forming portion 13 is provided in the first portion 11, when a plurality of electromagnetic steel sheets 90 are laminated, a plurality of fins 14 are formed by these fin forming portions 13. Heat is transmitted to these fins 14 and exposed to the outside air, so that the heat generated by the core 1 can be released. This allows the reactor 100 to operate more stably.

[0024] Furthermore, in the above configuration, of the three second portions 12, the second portion 12 located at the center in the first direction D1 has a smaller dimension in the second direction D2 than the other second portions 12.

[0025] According to the above configuration, an air gap can be formed between the second portion 12 located at the center and the central component 1b facing it. Although heat generation is likely to increase at the base of the second portion 12 located at the center (i.e., the connection portion with the first portion 11), the provision of the fin forming portion 13 on the first portion 11 allows the heat generation to be efficiently released to the outside.

[0026] In the above configuration, the dimension of the central part 1b in the first direction D1 is twice the dimension of the second portion 12 in the second direction D2. Furthermore, the dimension of the central part 1b in the second direction D2 is the same as the distance between the second portions 12 in the first direction D1.

[0027] According to the above configuration, it is possible to improve the yield of the plate material used when forming the central component 1b and the outer components 1a by punching. In other words, it is possible to reduce waste. Specifically, the dimension of the outer component 1a in the second direction D2 is set to be twice the protruding length of the second portion 12. As a result, when a pair of outer components 1a are combined so that the second portions 12 face each other and punched, the region formed between the second portions 12 can be used as the central component 1b without waste.

[0028] In addition, in the above configuration, of the pair of outer parts 1a, the position of the fin forming portion 13 in one outer part 1a in the first direction D1 is different from the position of the fin forming portion 13 in the other outer part 1a in the first direction D1, and when the fin forming portions 13 are faced to each other in the second direction D2, the fin forming portions 13 are shaped to engage with each other.

[0029] According to the above configuration, when the outer parts 1a are punched while being connected to each other in the second direction D2, the fin forming portions 13 engage with each other, thereby reducing wasteful parts generated by the punching process and improving the yield.

[0030] (Other embodiments) The above describes the embodiments of the present disclosure. Various changes and modifications can be made to the above configuration without departing from the gist of the present disclosure. For example, in the above embodiment, an example has been described in which the fin forming portion 13 (fins 14) are arranged at equal intervals in the first direction D1. However, the form of the fins 14 is not limited to the above, and it is also possible to adopt a configuration in which the density of the fins 14 is high in the area where heat generation is most likely to increase (the position corresponding to the central second portion 12) and the density of the fins 14 is low in other areas.

[0031] Also, for example, as a modified example when punching a flat workpiece W (base material), it is also possible to adopt a shape as shown in FIG. 3A.

[0032] In the punching process, a die (blade) having a shape as shown by a solid line in Fig. 3A is used to punch out parts from the workpiece W. Hereinafter, the configuration of a group of multiple outer parts 10a formed by punching the workpiece W will be described.

[0033] The multiple outer part groups 10a are arranged adjacent to each other in the direction in which the workpiece W extends. Each outer part group 10a is formed by arranging multiple pre-assembly outer parts 1a' having the same shape in one direction in an integrated state. Note that the outer component group 10a arranged at the end in the direction in which these outer component groups 10a are adjacent to each other may be constituted by, for example, one pre-assembly outer component 1a'.

[0034] Each pre-assembled outer part 1a' in each outer part group 10a has a first portion 11' extending in a first direction D1 and three second portions 12' protruding from this first portion 11' in a second direction D2 and arranged at intervals in the first direction D1.

[0035] In the example of FIG. 3A, among the two second parts 12′ arranged on the outside of the three second parts 12′ arranged in the first direction D1 of the pre-assembly outer part 1a′, the length in the second direction D2 of one second part 12′ is shorter than the length in the second direction D2 of the other two second parts 12′ having the same length. Hereinafter, for convenience of explanation, among the two second parts 12′ arranged on the outside of the three second parts 12′, the second part 12′ (the one second part 12′) having the shorter length in the second direction D2 is referred to as the “second part 12a”, and the other second part 12′ is referred to as the “second part 12b”. In addition, the second part 12′ arranged between the second part 12a and the second part 12b is referred to as the “second part 12c”. Therefore, the length of the second part 12b in the second direction D2 is the same as the length of the second part 12c in the second direction D2.

[0036] The second portion 12a of each pre-assembly outer part 1a' in one outer part group 10a is arranged in the workpiece W so as to engage with the second portion 12a of the pre-assembly outer part 1a' in the other outer part group 10a adjacent to the one outer part group 10a. The term "engage" here means a state in which the second portion 12a of the pre-assembly outer part 1a' in the other outer part group 10a is arranged in the workpiece W so as to fit between the second portion 12a and the second portion 12c of the pre-assembly outer part 1a' in the one outer part group 10a without any gap. Note that the second portion 12a of the pre-assembly outer part 1a' arranged on one side of the ends in the one direction in the one outer part group 10a may be arranged in the workpiece W, for example, without engaging with the second portion 12a of the pre-assembly outer part 1a' in the other outer part group 10a adjacent to the one outer part group 10a.

[0037] At the same time, the second portion 12b of the pre-assembled outer part 1a' in one outer part group 10a is aThe pre-assembly outer part 1a' is disposed in the workpiece W so as to engage with the second portion 12b of the pre-assembly outer part 1a' in the other outer part group 10a adjacent to the one outer part group 10a. Here, "engage" means a state in which the pre-assembly outer part 1a' in the other outer part group 10a is disposed in the workpiece W so as to fit between the second portion 12b and the second portion 12c of the pre-assembly outer part 1a' in the one outer part group 10a without any gap. Note that the second portion 12b of the pre-assembly outer part 1a' disposed on one side of the ends in the one direction in the one outer part group 10a may be disposed in the workpiece W, for example, without engaging with the second portion 12b of the pre-assembly outer part 1a' in the other outer part group 10a adjacent to the one outer part group 10a.

[0038] In this case, of two pre-assembly outer parts 1a' adjacent to each other in one outer part group 10a, the second portion 12c of one pre-assembly outer part 1a' is integrally connected in the first direction D1 to an end edge in the first direction D1 of the first portion 11' of the other pre-assembly outer part 1a'. In FIG. 3A, this connection portion is indicated by a dotted line. In this case, the second portions 12c of the pre-assembly outer parts 1a' of adjacent outer part groups 10a are arranged in the workpiece W so as to abut against each other without any gaps in the second direction D2.

[0039] Furthermore, when the length of the second portion 12a in the second direction D2 is L, the width (length) of the first portion 11' in the second direction D2 is L1, and the length of each of the second portion 12b and the second portion 12c is L2, the following formula (i) holds. L ≦ L2-2 × L1 … (i) That is, of the two second portions 12' located on the outside in the first direction D1 and having different lengths in the second direction D2, the length L in the second direction D2 of the shorter second portion 12' (second portion 12a) is less than the difference between the length L2 in the second direction D2 of the other second portion 12' (second portion 12b and second portion 12c) and twice the width L1 (length) in the second direction D2 of the first portion 11'.

[0040] Here, L1 and L2 on the right side of the above formula (i) are each a preset fixed value. In other words, the length of L can be freely set as long as it is equal to or less than the length (constant) indicating the difference between L2 and twice L1.

[0041] The above formula (i) is valid as an equality when no surplus portion X is formed. On the other hand, when the surplus portion X is formed, the above formula (i) is valid as an inequality in which the left side of the formula (i) is smaller than the right side by the dimension of the surplus portion X in the second direction D2.

[0042] By satisfying such dimensional conditions, an excess portion X is formed between the first portion 11' of the pre-assembly outer part 1a' in one outer part group 10a and the first portion 11' of the pre-assembly outer part 1a' in the other outer part group 10a. The length of the second portion 12c in the first direction D1 is, for example, approximately twice the length of the second portion 12a and the second portion 12b in the first direction D1.

[0043] The outer component group 10a formed by punching is divided into each pre-assembly outer component 1a' to form a plurality of outer components 1a. Specifically, the outer component group 10a is cut along the dotted lines in FIG. 3A to form a plurality of outer components 1a. Furthermore, the surplus portion X formed by the punching process can be utilized as the above-mentioned fin forming portion 13. Second direction D2 The dimension of the fin 13 can be adjusted by changing the width L1 of the first portion 11' in the second direction D2 and the length L of the second portion 12a in the second direction D2. Therefore, the length of the fin 13 in the second direction D2 can be easily adjusted.

[0044] Moreover, according to the above configuration, among the second portions 12 of the outer component 1a, the second portions 12 having a shorter length are disposed in the workpiece W in a state of being engaged with each other, thereby making it possible to suppress the generation of wasted portions during punching. In addition, the surplus portion X generated between two adjacent first portions 11 can be utilized as the fin forming portion 13, thereby making it possible to further improve the yield.

[0045] Furthermore, according to the shape of the punching process described above, a plurality of outer parts 1a having the same shape can be formed from the workpiece W. That is, the workpiece W is punched out so that one second portion 12 of the plurality of outer parts 1a having the same shape engages with each other, thereby forming a plurality of pairs of outer parts 1a. Therefore, the yield can be further improved.

[0046] Also, for example, a shape as shown in FIG. 3B may be adopted as a modified example when punching a workpiece W (base material) having a flat plate shape. The pre-assembly outer part 1a' of the modified example shown in FIG. 3B is different from the pre-assembly outer part 1a' shown in FIG. 3A in the length of the second part 12c in the second direction D2. Specifically, the length of the second part 12c shown in FIG. 3B in the second direction D2 is shorter than the length of the second part 12c shown in FIG. 3A in the second direction D2, and is longer than the length of the second part 12a in the second direction D2. That is, the protruding lengths of the three second parts 12' of the pre-assembly outer part 1a' from the first part 11' in the second direction D2 change in the order of arrangement in the first direction D1, and the lengths in the second direction D2 are shorter in the order of the second part 12b, the second part 12c, and the second part 12a. Hereinafter, the same reference numerals are used in the figure for the configurations common to the configurations described using FIG. 3A, and the description thereof will be omitted.

[0047] 3B, the length of the second portion 12a in the second direction D2 is L', the width (length) of the first portion 11' in the second direction D2 is L1', and the length of the second portion 12c is L2'. In this case, L' and L2' satisfy the following formula (ii) in relation to L1' and L3. 2×L2´―L´≧2×L1´+L3 …(ii)

[0048] Here, L1' and L3 on the right side of the above formula (ii) are each a preset fixed value. In other words, the length indicating the difference between L' and twice L2' can be freely set as long as it is equal to or greater than the length (constant) indicating the sum of L1' and L3.

[0049] The above formula (ii) is established as an equality when no surplus portion X is formed. On the other hand, when a surplus portion X is formed, the above formula (ii) is established as an inequality in which the left side of the formula (ii) is larger than the right side by the dimension of the surplus portion X in the second direction D2. Furthermore, when L3 and L2' are equal (L3=L2'), L'≦L2'-2×L1' holds, and the above formula (i) holds.

[0050] The configuration described above with reference to FIG. 3B can also achieve the same effects as those achieved by the configuration described with reference to FIG. 3A.

[0051] In addition, as a modified example when punching a flat workpiece W (base material), it is also possible to adopt a shape as shown in Fig. 4. Hereinafter, the same reference numerals will be given to the configurations in common with those described using Fig. 3A and Fig. 3B, and the description thereof will be omitted.

[0052] The pre-assembled outer component 1a' described with reference to Fig. 4 does not have the second portion 12a that the pre-assembled outer component 1a' described with reference to Figs. 3A and 3B has. In other words, the length of one second portion 12 located on the outside (the second portion 12a described with reference to Figs. 3A and 3B) is set to 0.

[0053] The second portion 12b of the pre-assembled outer part 1a′ in one outer part group 10a is aThe first portion 11' of the pre-assembly outer part 1a' in the one outer part group 10a and the other outer part group 10a adjacent to the one outer part group 10a are disposed in the workpiece W so as to engage with the second portion 12b of the pre-assembly outer part 1a' in the other outer part group 10a adjacent to the one outer part group 10a. Among the portions outer than the second portion 12c of the first portion 11' of the pre-assembly outer part 1a' in each of the one outer part group 10a and the other outer part group 10a adjacent to the one outer part group 10a, the portions opposite to the second portion 12b abut against each other in the second direction D2.

[0054] The length L3' in the second direction D2 of the second portion 12c of each pre-assembly outer part 1a' is longer than twice the width L4 (length) in the second direction D2 of the first portion 11'. By satisfying such dimensional conditions, a surplus portion X is formed between the pre-assembly outer part 1a' in one outer part group 10a and the pre-assembly outer part 1a' in the other outer part group 10a.

[0055] The above-mentioned configuration described with reference to Fig. 4 can achieve the same effect as that achieved by the configuration described with reference to Fig. 3A and Fig. 3B. In addition, since the pre-assembly outer component 1a' does not have the second portion 12a, it is possible to secure an excess portion X of the length of the second portion 12a in the second direction D2 in comparison with the configuration described with reference to Fig. 3A and Fig. 3B. In other words, by arranging the second portions 12 each having a length of 0 in a state of facing each other, it is possible to maximize the size of the excess portion X formed between two adjacent first portions 11. In other words, when utilizing this excess portion X as the fin forming portion 13, it is possible to maximize the fin forming portion 13.

[0056] Moreover, by using the pre-assembly outer part 1a' described with reference to Figs. 3A, 3B, and 4, a reactor 100 which will be described below with reference to Fig. 5 can be configured. In FIG. 5, a case will be described as an example in which the pre-assembly outer part 1a' described with reference to FIG. 3B is used to configure this reactor 100.

[0057] As shown in FIG. 5, the reactor 100 includes a core 1 and two coils (a first coil 51 and a second coil 52).

[0058] (Core configuration) The core 1 is formed by laminating a plurality of plate-shaped reactor electromagnetic steel sheets 90 in the thickness direction, as in the above-described embodiment. The reactor electromagnetic steel sheet 90 has a pair of outer parts 1a and a central part 1b. The outer parts 1a are obtained by separating a plurality of pre-assembly outer parts 1a' constituting the outer part group 10a described with reference to FIG. 3B from each other.

[0059] The outer component 1a has a first portion 11 extending in a first direction D1, three second portions 12 extending in a second direction D2 from a long side of the first portion 11, and a fin forming portion 13 provided on an edge of the first portion 11 opposite to the second portions 12. The first portion 11 here corresponds to the first portion 11' described with reference to Fig. 3B, and the second portion 12 corresponds to the second portion 12' described with reference to Fig. 3B.

[0060] A pair of outer components 1a having such a shape are provided in a position that is point-symmetric with respect to the first direction D1.

[0061] The central component 1b has a third portion 23 extending in the first direction D1, and two protruding portions 24 protruding from both ends of the third portion 23 in the first direction D1 so as to be spaced apart from each other in the second direction D2.

[0062] The third portion 23 connects an end of a second portion 12 (second portion 12b) that is located on the outside in the first direction D1 among the three second portions 12 in one outer part 1a to an end of a second portion 12 (second portion 12b) that is located on the outside in the first direction D1 among the three second portions 12 in the other outer part 1a.

[0063] The protruding length of the protruding portion 24 in the second direction D2 is equal to the length of the second portion 12 (second portion 12a) that is shorter in the second direction D2 minus the length of the second portion 12 (second portion 12b) that is longer in the second direction D2 among the second portions located on the outer side in the first direction D1. This protruding portion 24 abuts against the second portion 12 (second portion 12a) in the second direction D2.

[0064] (Coil configuration) First coil 51 and second coil 52 are each formed by winding a wire several times around second portion 12 disposed at the center in first direction D1. That is, reactor 100 has two independent coils. Various modes proposed so far can be adopted as a method of winding the wire.

[0065] At this time, a gap S (air gap) is formed between the first coil 51 and the second coil 52 and the third portion 23 of the central component 1b. Furthermore, since the protruding length of the protruding portion 24 of the central component 1b in the second direction D2 satisfies the above-mentioned dimensional conditions and this protruding portion 24 abuts against the second portion 12 (second portion 12a) in the second direction D2, a gap S is formed between the second portion 12 (second portion 12c) that is located in the center of the three second portions 12 of the outer component 1a and the third portion of the central component 1b.

[0066] (Regarding the punched shape of the central part) Next, the punched shape of the central part 1b will be described with reference to Fig. 6. During punching, the part is punched out from the workpiece W by a die (blade) having a shape as shown by a solid line in Fig. 6.

[0067] As shown in Fig. 6, the multiple pre-assembly central parts 1b' arranged in the work W are arranged such that the third portions 23' and the protruding portions 24' extending from the third portions 23' face each other in one direction and are arranged in a pair with no gaps. Furthermore, pairs each made up of multiple pre-assembly central parts 1b' are arranged in the work W such that multiple pairs are continuously laid out in a direction intersecting the one direction. In this way, the multiple pre-assembly central parts 1b' are punched out of the work W, and each pre-assembly central part 1b' becomes a central part 1b.

[0068] FIG. 5 shows an example of the direction in which magnetic flux generated around first coil 51 and second coil 52 flows when reactor 100 is driven (arrow A). By winding the coils (first coil 51 and second coil 52) around the second portion 12 (second portion 12c) located at the center in the first direction D1, the amount of loss generated is doubled compared to a normal EI core configuration in which one coil is mounted on one core 1. In contrast, the surface area of ​​the core 1 remains, for example, less than twice that of a normal EI core, so the ratio of the surface area per unit heat generation in the core 1 is lower than that of a normal EI core, and the temperature of the core 1 may increase further. Specifically, the surface area of ​​the core 1 remains, for example, 136% of the surface area of ​​a normal EI core, and in this case, the ratio of the surface area per unit heat generation in the core 1 is 68.2% of that of a normal EI core. Note that the "normal EI core" referred to here means that the electromagnetic steel sheet 90 has one outer part 1a and one central part 1b, the two second portions 12 (second portion 12a and second portion 12b) arranged on the outside of the outer part 1a in the first direction D1 have the same length, and the central part 1b has only the third portion 23.

[0069] According to the above configuration, a gap S serving as an air gap is formed between the second portion 12c and the third portion 23, and the gap S attenuates the flow of magnetic flux, thereby suppressing the amount of heat generated at the centers of the second portion 12c and the third portion 23. On the other hand, in first portion 11, since the gap S is not formed, the magnetic flux does not attenuate and the iron loss increases, so that first portion 11 is likely to generate heat. According to the above configuration, since first portion 11 is provided with fin forming portion 13 for heat dissipation, the heat of first portion 11 is dissipated by this fin forming portion 13. As a result, heat is less likely to accumulate in first portion 11. Therefore, it is possible to suppress the accumulation of heat in the core 1 and to make the temperature of the entire core 1 uniform.

[0070] In addition, since the gap S is formed, the first coil 51 and the second coil 52 can be cooled by the air present in the gap S. Therefore, an increase in the temperature of the core 1 can be suppressed.

[0071] Furthermore, according to the above configuration, when punching out the central components 1b, the central components 1b can be punched out from the workpiece W without forming gaps between the central components 1b. Therefore, the yield rate can be improved when forming the central components 1b. In forming the reactor 100, the outer pre-assembly part 1a' described with reference to Figs. 3A and 4 may be used.

[0072] [Note] The reactor 100 described in the embodiment can be understood, for example, as follows.

[0073] (1) A reactor 100 according to a first aspect includes a core 1 made of a plurality of electromagnetic steel sheets 90 stacked in the thickness direction, and coils (first coil 51, second coil 52) made of wire wound around the core 1, in which the electromagnetic steel sheets 90 have a pair of outer parts 1a having a first portion 11 extending in a first direction D1 and a plurality of second portions 12 extending from the first portion 11 in a second direction D2 perpendicular to the first direction D1 and arranged at intervals in the first direction D1, a central part 1b connecting the second portions 12 to each other in the first direction D1 with the second portions 12 facing each other in the second direction D2, and a plurality of fin forming portions 13 protruding in the second direction D2 from an edge of the first portion 11 opposite the second portion 12 and arranged at intervals in the first direction D1.

[0074] According to the above configuration, since the fin forming portion 13 is provided in the first portion 11, when a plurality of the electromagnetic steel sheets 90 are laminated, a plurality of fins 14 are formed by these fin forming portions 13. This allows heat generated in the core 1 to be released to the outside.

[0075] (2) A reactor 100 according to a second aspect is the reactor 100 of (1), wherein, among the multiple second portions 12, the second portion 12 located at the center in the first direction D1 may have a smaller dimension in the second direction D2 than the other second portions 12.

[0076] According to the above configuration, an air gap can be formed between the second portion 12 located at the center and the central component 1b facing it. Although heat generation is likely to increase at the base of the second portion 12 located at the center (i.e., the connection portion with the first portion 11), the provision of the fin forming portion 13 on the first portion 11 allows the heat generation to be efficiently released to the outside.

[0077] (3) The reactor 100 according to a third aspect is the reactor 100 of (1) or (2), wherein the dimension of the central part 1b in the first direction D1 may be twice the dimension of the second part 12 in the second direction D2.

[0078] According to the above configuration, it is possible to improve the yield of the plate material used when forming the central component 1b and the outer components 1a by punching. In other words, it is possible to reduce waste. Specifically, when a pair of outer components 1a are combined with each other so that the second portions 12 face each other and punched, the area formed between the second portions 12 can be used as the central component 1b without waste.

[0079] (4) A reactor 100 according to a fourth aspect is any one of the reactors 100 (1) to (3), and the dimension of the central part 1b in the second direction D2 may be the same as the spacing dimension between the second portions 12 in the first direction D1.

[0080] According to the above configuration, when a pair of outer components 1a are combined so that the second portions 12 face each other and punched, the area formed between the second portions 12 can be used as the central component 1b with no waste.

[0081] (5) A reactor 100 according to a fifth aspect is a reactor 100 according to any one of (1) to (4), wherein the position of the fin forming portion 13 in one of the pair of outer parts 1a in the first direction D1 is different from the position of the fin forming portion 13 in the other outer part 1a in the first direction D1, and the fin forming portions 13 may be shaped to engage with each other when the fin forming portions 13 are opposed to each other in the second direction D2.

[0082] According to the above configuration, when the outer parts 1a are punched while being connected to each other in the second direction D2, the fin forming portions 13 engage with each other, thereby reducing wasteful parts generated by the punching process and improving the yield.

[0083] (6) A reactor 100 according to a sixth aspect is the reactor 100 of (1), wherein a workpiece W is punched out so that the second portions 12 of a plurality of the outer parts 1a having the same shape engage with each other, thereby forming a plurality of pairs of the outer parts 1a, and the outer parts 1a have three of the second portions 12, are positioned on the outside in the first direction D1, and one of two second parts 12 having different lengths in the second direction D2, the length of the one second portion 12 having the shorter length, may be less than the difference between the length of the other second portion 12 in the second direction D2 and twice the width of the first portion 11 in the second direction D2.

[0084] According to the above configuration, among the second portions 12 of the outer component 1a, the second portions 12 having a shorter length are arranged in an engaged state, thereby making it possible to suppress the generation of wasted portions during punching. In addition, by satisfying the above-mentioned dimensional conditions, when the second portions 12 are engaged with each other, an excess portion X is formed between two adjacent first portions 11. This excess portion X can be used as a fin forming portion 13.

[0085] (7) A reactor 100 according to a seventh aspect is the reactor 100 of (6), wherein the three second portions 12 have different lengths in the second direction D2 in the order in which they are arranged in the first direction D1, and the difference between twice the length in the second direction D2 of the second portion 12 located in the center in the first direction D1 and the length in the second direction D2 of one of the second portions 12 may be greater than the sum of twice the width in the second direction D2 of the first portion 11 and the length of the second portion 12 with the longest length in the second direction D2.

[0086] According to the above configuration, a gap S (air gap) is formed between the second portion 12 located at the center in the first direction D1 and the central component 1b, thereby suppressing heat generation in the second portion 12 and the central component 1b.

[0087] (8) The reactor 100 according to an eighth aspect is the reactor 100 of (6), wherein, among the plurality of second portions, one second portion located on the outside in the first direction may have a length in the second direction of 0.

[0088] According to the above configuration, the length of one second portion 12 is 0, that is, it does not exist. As a result, by arranging one second portion 12 having a length of 0 in a state where they face each other, it is possible to suppress the generation of a wasted portion during punching. In addition, it is possible to maximize the size of the surplus portion X formed between two adjacent first portions 11. As a result, when the surplus portion X is utilized as the fin forming portion 13, it is possible to maximize the fin forming portion 13. [Industrial Applicability]

[0089] According to the present disclosure, it is possible to provide a reactor that can be operated more stably. [Explanation of symbols]

[0090] 1...core 1a...outer part 1a'...outer part before assembly 1b...central part 1b'...central part before assembly 10a...group of outer parts 11, 11'...first part 12, 12', 12a, 12b, 12c...second part 13...fin forming part 14...fin 23, 23'...third part 24, 24'...protruding part 51...first coil 52...second coil 90...electromagnetic steel sheet 100...reactor D1...first direction D2...second direction S...gap W...work X...surplus part

Claims

1. A core made of a plurality of electromagnetic steel sheets laminated in a thickness direction; A coil made of a wire wound around the core; Equipped with The electromagnetic steel sheet is a pair of outer components each having a first portion extending in a first direction and a plurality of second portions extending from the first portion in a second direction perpendicular to the first direction and arranged at intervals in the first direction; a central part that connects the second portions to each other in the first direction while the second portions are opposed to each other in the second direction; a plurality of fin forming portions protruding in the second direction from an edge of the first portion opposite to the second portion and arranged at intervals in the first direction; having A workpiece is punched out so that the second portions of the plurality of outer parts having the same shape are engaged with each other, thereby forming a plurality of pairs of the pair of outer parts; The outer component has three second portions, The length of one of the second portions that is shorter among the two second portions that are located on the outer side in the first direction and have different lengths in the second direction is A reactor having a length in the second direction of the other second portion that is less than the difference between the length and twice the width in the second direction of the first portion.

2. The three second portions have different lengths in the second direction in the order in which they are arranged in the first direction, The difference between twice the length in the second direction of the second portion located at the center in the first direction and the length in the second direction of one of the second portions is The reactor according to claim 1 , wherein the length in the second direction is greater than a sum of twice the width of the first portion in the second direction and the length of the second portion, which has the longest length in the second direction.

3. The reactor according to claim 1 , wherein the length in the second direction of one of the second portions located on an outer side in the first direction is zero.

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